Stand-Alone Multi-Function Battery Manager

The present disclosure relates generally to systems and methods for a battery manager, and more particularly, to systems and methods for a battery manager that charges, discharges, and/or balances high voltage battery systems.

Batteries from battery powered heavy machinery often require that a specific state of charge (SoC) be achieved for multiple reasons. For example, high voltage batteries may require discharging in order to reach a specific SoC required by transportation regulations in instances when high voltage batteries are being transported overseas. A different SoC may be required when transporting high voltage batteries as cargo on land. In another example, charging a high voltage battery to a desired level may be preferred before the battery is placed in use, so as to provide sufficient power for a specific job. In addition, monitoring and controlling individual battery cell balancing may be useful to ensure a battery's longevity. Failure to consider a battery's state of charge during storage or transportation may increase the risk of a potentially hazardous condition or result in noncompliance with battery storage or transportation regulations. Further, the failure to consider SoC in preparation for use of a high volt battery may result in unnecessary battery replacements or waiting for a battery to charge, both of which may result in avoidable expenses due to idle delays. Thus, in order to help preserve the lifespan of a high voltage battery, comply with battery transportation or storage regulations, or prepare a high voltage battery for use, there exists a need for an all-in-one stand-alone battery managing system.

An exemplary method for maintaining charge control of a battery array is described in U.S. patent application Publication Ser. No. 17/081,296, published on Apr. 29, 2021 (“the '296 patent”). The method described in the '296 patent may include controlling a battery charge current and voltage using a Pulse Width Modulation (PWM) signal or an inductor to either establish a restricted battery charge current or battery voltage. While the method described in the '296 patent may be helpful for managing batteries, it might not be able to serve as an all-in-one stand-alone battery managing system.

The disclosed method and system of the present disclosure may solve one or more of the problems set forth above and/or other problems in the art. The scope of the current disclosure, however, is defined by the attached claims, and not by the ability to solve any specific problem.

In one aspect, a mobile battery manager for charging or discharging a stored battery system may include a converter, a resistive load, and a controller configured to charge or discharge the stored battery system to a desired state of charge determined at the mobile battery manager.

In another aspect, a stored battery management method for a stored battery system may include communicating with the stored battery system to receive stored battery system data; determining, from the stored battery system data, a battery system profile; and charging or discharging the stored battery system with a battery manager, the charging or discharging based on the battery system profile and a desired state of charge received at the battery manager.

In yet another aspect, a stored battery management method for a stored battery system may include communicating with the stored battery system to receive stored battery system data; determining, from the stored battery system data, a battery system profile; determining whether to charge or discharge the stored battery system and a corresponding charge or discharge rate based on the battery system profile; and charging or discharging the stored battery system at the corresponding charge or discharge rate.

Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “has,” “having,” “includes,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. In this disclosure, unless stated otherwise, relative terms, such as, for example, “about,” “substantially,” and “approximately” are used to indicate a possible variation of +10% in the stated value.

is a diagram illustrating an exemplary environmentof battery manager, according to aspects of the disclosure. Environmentmay include an electric powered mobile industrial machine, a selectively removable machine battery systemfor powering machine, and a battery managerfor charging, discharging and otherwise managing one or more machine battery systems. Battery managermay receive power from power source, and exchange data with a remote network database.

depicts machineas an electrically powered load-haul-dump (LHD) type mining machine, however, other types of machines are contemplated, such as, for example, hauling machines, articulated/dump trucks, backhoe loaders, mining shovels, cold planers, dozers, skid steer loaders, motor graders, etc. Machinemay include a battery support portionconfigured to receiving and electrically couple with the machine battery systemfor providing power to an electric drive system of machinehaving one or more electric drive motors. Machinemay be an all-electric machinefully powered by the machine battery system, or may be partially powered by the machine battery system, such as a hybrid-type drive additionally including an engine.

Machine battery systemmay be a high voltage battery pack including, for example, a plurality of modules including a plurality of cells, and one or more battery management systems having associated sensors. When not coupled to machine, as shown in, machine battery systemmay be in storage, such as in a warehouse awaiting use on machine. Alternatively, machine battery systemmay be in transport as freight or cargo. In either instance, machine battery systemis disconnected from machineand not in active use.

In an exemplary embodiment, after being used on machine, machine battery systemmay be swapped out for a freshly charged battery and dropped off for temporary storage. Machine battery systemmay be stored for a period of time, may require preparation for next use, or may require preparation for transport. Additionally, machine battery systemmay require a status update or safety protocol to determine its health and fitness.

Battery managermay include different components to perform different protocols on machine battery system. Machine battery systemmay connect to battery managervia connection terminal. Connection terminalmay include any known types of high voltage electrical connectors, such as a standard J1772 connector (J plug or Type). In certain embodiments, battery managermay require power and may include a power connectionconnected to a power source. While the exemplary environmentdepicts power sourceas an AC power grid, other forms of power may be sourced, such as an AC-DC generator, batteries, etc. Upon connection via connection terminal, battery managermay utilize a battery controller systemincluding battery controllerto perform different protocols on machine battery system. As will be discussed in greater detail in, battery controllermay receive input information from user interfaceand process the information using processors and/or memory devices to determine various outputs or protocols to perform in relation to machine battery system. User interfacemay be simple in nature and display. For example, user interfacemay merely receive, as entered by a user, a desired SoC and/or storage or transportation information, and battery managerwill determine and perform all the necessary steps and/or procedures without any additional monitoring by the user. If battery manageris in the middle of operation, a user may simply view the user interface to observe a snapshot of the battery system, e.g. current SoC, temperature, safety checks, use and maintenance logs, etc.

In one exemplary embodiment, battery controllermay utilize safety circuitsto perform a safety check protocol on machine battery system. Safety circuitsmay include a multimeter, calorimeter, a battery impedance tester, or other known methods and equipment to determine a status of machine battery system, both as an overall battery systems array and as individual battery cells of the overall array.

Battery controllermay utilize a resistive loadto discharge machine battery systemto a desired state of charge (SoC). Resistive loadmay include, for example, a variety of different sized resistors in order to add different sized loads to machine battery system, such that stored energy of machine battery systemmay be dissipated to a desired SoC at a desired rate and/or in a desired amount of time. Battery controllermay determine the desired SoC, for example, based on information received at user interface, and adjust resistive loadaccordingly.

Battery controllerof battery managermay also determine that machine battery systemis to be charged. Battery controllermay utilize converterto convert energy from power sourceto machine battery system. Convertermay include, for example, a rectifier including one or more of switches, inductors, transformers, capacitors and diodes. In one exemplary embodiment, battery controllermay direct power from power sourceto charge machine battery systemto a desired SoC, at a specific rate of charge, or in a specific amount of time.

In an exemplary embodiment, battery managermay be installed as part of a mobile systemso as to be easily navigable to different machine battery systems. In one exemplary embodiment, mobile systemmay include a manual cart that allows battery managerto be rolled easily on flat surfaces. In addition, battery managermay include a transmission device that allows for transmission of information and data related to machine battery systemand battery managerto network database. The transmission device could include, for example, a wired or wireless transmission device including, for example, one or more antenna, transmitters, and receivers, etc.

is a diagram of battery controller systemof the battery manager. As noted above, battery controller systemmay include battery controllerreceiving inputs such as battery dataand user interface data. Battery controllerprocesses the input information via an initialization module, a battery management module, and/or a reporting module. Battery controllermay provide one or more outputs such as battery data, user interface data, a charge/discharge command, and telematics data, each of which will be discussed below.

Battery controllermay embody a single microprocessor (CPU) or multiple microprocessors, a memory, a databaseor secondary storage device, and/or any other means for accomplishing a task consistent with the present disclosure. The memory or databaseassociated with battery controllermay store data and/or software routines that may assist battery controllerin performing its functions, such as the functions of methodof. In addition, the memory or databaseassociated with battery controllermay store data received from the various inputs associated with battery controller system. Further, memory or databasemay include SoC regulations for transporting or storing, for example, as a function of location and/or a shipping process. Numerous commercially available microprocessors can be configured to perform the functions of battery controller. Battery controllermay embody a non-transitory machine-readable medium that stores information that, when executed by battery controller, causes the battery controller systemto perform instructions and may be computer-implemented. It should be appreciated that battery controllercould readily embody a general machine controller capable of controlling numerous other machine functions. Alternatively, a special-purpose machine controller could be provided. Further, one or more operations of battery controller, may be performed remote over a network through network databaseand communicated to battery manager. Various other known circuits may be associated with battery controller, including signal-conditioning circuitry, communication circuitry, actuation circuitry, and other appropriate circuitry.

As noted above, inputs of controllermay include battery dataand user interface data. Battery datamay be provided upon using connection terminalto connect machine battery systemto battery manager. Battery datamay include stored battery system data such as a battery profile and charge information such as battery type, SoC, voltage, physical size, manufacturing date, etc. Battery datamay also include usage data such as machinecompatibility, dates, times, and locations of usage, ownership, assigned projects, next in-use date, etc. User interface datamay include information provided by a user via user interface. User interface datamay include receiving input such as a desired state of charge, time to charge, time to discharge, or an indication to perform a safety check.

After connection of battery managerwith battery machine systemvia connection terminal, battery controllermay proceed with an initialization via initialization module. This module may be performed upon receiving battery datathat includes information that an initial “handshake” connection between battery managerand machine battery systemhas been made. Using safety circuits, battery controllermay analyze machine battery systemto test fluid levels, temperature, or operability. Safety circuitsmay also test machine battery systemfor connectivity, proper grounding, or any leakage. Battery controllermay also perform a battery load test as part of the initialization module to determine initial battery parameters. Other tests may be performed to determine an overall safety compliance of the complete battery system or tests may be performed to determine the health and functionality of each individual battery cell of machine battery system.

In addition, battery controllermay perform battery management via battery management module. Battery management modulemay include charging or discharging machine battery system, depending on the inputs of battery dataand user interface data. In an exemplary embodiment, battery management modulemay determine a desired state of charge and how to achieve the desired state of charge. For example, battery controllermay determine that machine battery systemneeds to be charged in instances where the current state of charge is lower than the desired charge. Alternatively, battery controllermay determine that machine battery system needs to be discharged in instances where the current state of charge is higher than the desired charge. Battery management modulemay consider other parameters such as time to charge or discharge, rate at which to charge or discharge, total duration of charging or discharging, etc.

Battery controllermay also perform a reporting via a reporting module. Reporting modulemay include preparing a report that includes information of machine battery systemincluding any of the information noted above, such as battery dataincluding profile information and/or battery charge information, safety check information, and/or charging or discharging activity. The information prepared by reporting modulemay be stored in a database, and/or may be sent to remote network databasefor access over various platforms.

As outputs, battery controllermay provide battery datathat includes information and parameters such as the battery datamentioned above as an input to controller. For example, input battery datamay include data related to what is needed to manage machine battery systemand output battery datamay include data or information that confirms or relates to machine battery systemoperating properly and efficiently. In one exemplary embodiment, machine battery systemmay export battery datato battery managerand then sent as battery datato network database. In another embodiment, battery datamay be exported as a printable paper report to be printed or saved by an attached computer. In another exemplary embodiment, battery datamay be provided and continually updated to user interfaceso that users may be able to view user interfaceand determine the current charging or discharging status of machine battery system. User interface datamay include a status, such as “initializing”, “charging”, “discharging”, “paused”, or “complete” along with any of the other data discussed above.

As previously discussed, battery controllermay output a charge/discharge commandto enable battery managerto supply charge to, or discharge charge from, maching battery system. The charge/discharge commandmay also include a rate at which to charge/discharge, a duration of charge/discharge, based on a desired SoC. In addition, a charge/discharge commandmay include a stop command upon the SoC goal being achieved. In another exemplary embodiment, a charge/discharge commandmay include a maintain SoC command where a small trickle charge is provided to offset any small battery power leakage or discharge.

Outputs may also include telematics datawherein battery managermay transmit battery data, e.g., via a wireless networks, to a remote server, such as remote network databasefor storage, processing, tracking, and access over a network.

provides a flowchart of methoddepicting an exemplary method for battery manager. In an exemplary embodiment, the process may perform stepand establish communication by using connection terminalto physically connect machine battery systemwith battery manager. Upon establishing communication, initialization modulemay confirm a data connection or “handshake” between the systems and perform a safety check (step) on machine battery system. The safety check may include checking fluid levels, monitoring temperature, verifying connectivity and proper grounding, or determine the overall safety of machine battery system. Other tests may be performed to determine an overall safety compliance of the machine battery system. Additionally, safety tests may be performed to determine the health and functionality of each individual battery cell of machine battery system, including performing battery cell balancing as needed.

Methodmay then perform stepand determine a battery system profile based on battery dataand user interface data. An example of a battery system profile may include the characteristics of the battery including type, size, SoC, machine compatibility, etc. A battery system profile may further include a storage profile including where machine battery systemmay be stored for a period of time. A storage profile may be further broken down into long term storage or short term storage depending the period of time machine battery system is set or intended to be stored. Another example of a battery profile system may include a transport profile for batteries that are to be transported. The transport profile may be further defined by the type of carrier, such as by a ship, barge, train, truck or plane. Alternatively, the transport profile may be further defined by an initial location of origin or the final destination. In another embodiment, the travel profile may include a location of the job site. A battery system profile may include other profiles as determined by a user entering the profile through user interfaceand/or received from the machine battery system, received via network database, or received via database. For example, a remote server associated with network databasemay include a catalogue of machine battery systems and may change, update, or provide battery system profiles on battery manager.

In the exemplary embodiment, methodmay include stepof receiving a desired SoC input. The SoC input may be received, via user interfaceas user interface datato be added to the battery system profile and/or may be received via a remote server associated with network database, or may be retrieved from databasethat associates a desired SoC based on other battery system profile data. An SoC input may include a time component, such as when maintaining an SoC for a particular period of time. A state of charge may also include a voltage requirement. For example, a desired SoC may be 1000 volts. Alternatively, a SoC may be a percentage, such as 30%, where 0% is completely discharged and 100% is fully charged. An SoC may also have a time component, such as when maintaining an SoC of machine battery systemfor a particular period of time. In another exemplary embodiment, a desired SoC may be associated with a regulation for storing or transporting machine battery system. Rather than receiving an SoC input, a user may input profile information, such as a storage location or a transportation process, via user interface. Databasemay then be accessed and based on the input profile information, determine the desired SoC.

Stepmay include charging or discharging machine battery systembased on the desired SoC input. Charging or discharging may be performed at a charge or discharge rate determined by battery management module. For example, an immediate need for machine battery systemmay arise and battery management modulemay charge machine battery systemat the highest charge rate possible until it is fully charged. Alternatively, battery manager, through battery management modulemay determine that machine battery systemis to be reduced to a 50% SoC so that it will comply with transport regulations when it is shipped out in two days. In this example, battery controllermay discharge a machine battery systemat a rate such that machine battery systemwill finish discharging in two days. In this example, it may be beneficial to end discharging on the day of transportation because if discharging were to be completed earlier, machine battery systemmay lose additional charge, such as through self-discharging, and thus not correspond with the desired shipping SoC.

Methodincludes step, terminating the charge or discharge when the desired SoC is met. In continuation of the example above, discharging may be terminated when machine battery systemreaches a SoC of 50%. In another example, charging machine battery systemmay be terminated when machine battery systemhas reached a rated maximum SoC of the machine battery systemand is considered fully charged.

Lastly, in this exemplary embodiment, methodmay include providing battery system information to a network database, or cloud based server, in the form of telematics data. System information may include duration of charge, final SoC, time charging or discharging was completed, or other relevant charging parameters.

The disclosed method has applicability in industry by providing a system for effectively managing a machine battery system. For example, the disclosed battery managermay monitor and manage a machine battery systemthat is disconnect from its associated industrial machine, and requires a particular charge or discharge to establish a desired SoC. The desired SoC may be required for various reasons, such as to comply with storage and/or transportation regulations for battery systems.

The above described battery managerand associated method provides an all-in-one stand-alone system for managing a machine battery system. Managing high voltage batteries may include charging or discharging a machine battery systemto a set SoC. The SoC may be easily provided by a user through a simple user interface. Alternatively, a user may provide other information, such as a location if machine battery systemis being stored, or a route if machine battery systemis being transported. Databasemay be accessed to determine any applicable government regulations to consider when determining the SoC for the machine battery system. Thus, management of machine battery systemrequires minimal input and oversight. In addition, the mobility of battery managerallows for battery managerto be easily moved in order to manage multiple machine battery systems at various locations. Also, battery managermay perform a safety check to ensure the fitness and health of machine battery systemis appropriate.

It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed system without departing from the scope of the disclosure. Other embodiments of the system will be apparent to those skilled in the art from consideration of the specification and practice of the system disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.